Outdoor electrical outlet cover

ABSTRACT

An outlet enclosure for enclosing an electrical outlet to cover the electrical outlet and its electrical socket. The outlet enclosure includes a base plate and an outlet cover or holder which wraps partially around the electrical outlet to allow access to the electrical socket. The outlet cover or holder includes tracks extending in a vertical direction along its outer surface. An outer cylindrical cover wraps completely around the outlet cover or holder. The outer cylindrical cover slides vertically via the tracks over the outlet cover or holder from a lowered position fully enclosing the outlet cover or holder to a raised position exposing the electrical socket to allow access to the electrical outlet so that a plug can be inserted into the socket of the electrical outlet. When the outer cylindrical cover is lowered, it protects the electrical outlet from exposure to the elements.

FIELD OF THE INVENTION

The present invention relates to a cover for concealing an electricaloutlet which is installed exterior to a building, house or otherstructure or area that is accessible by electricity. The electricaloutlet is known as a WR-GFCI with a waterproof vertical cover and a mayinclude a waterproof self-closing door of the type available fromHubbell Industries.

The electrical outlet or switch can be an electrical socket such as a120 volt socket which accepts a three prong electrical plug, or anyother socket configuration as determined by local regulations and laws.

BACKGROUND OF THE INVENTION

When electrical outlets are installed at outdoor locations, whether abuilding site or finished building or a home, such outlets must havecertain features and characteristics which are needed to comply withwhat is known as the UL-231 standard and UL 514 A and UL 514 D. Anexterior outlet to be certified by UL must first meet the NEMA 4X/IP65(“NEMA”) certifications as an electrical enclosure. The NEMAcertification that this outlet will be certified for, will be adesignation of 4X. Normal exterior outlets do not need to meet the highstandards of a NEMA exterior enclosure with a 4X certification. This isone of the most difficult to obtain since the exterior enclosure mustwithstand moisture, dirt, dust, rain, sleet, snow, ice and hose directedwater.

Such outlets typically are installed within a cover which is in thenature of a flap or door on the external surface of the outlet which canbe opened so that an electric plug can be inserted into a socket of theoutlet and closed when the electric plug is removed. For this type ofoutlet cover the actual cover must comply with code article 406.9B ofthe NEC code. The code requires that the receptacles must use a “whilein use cover” that is identified as “Extra duty” Although such covershide the electrical outlet/socket, when installed on an electricalconduit six inches off the ground, the result is usually not pleasing tothe eye.

BRIEF SUMMARY OF THE INVENTION

The invention is directed to an outlet enclosure for a stand-aloneelectrical outlet intended for an outdoor installation. That is, theoutlet and outlet enclosure extend from a ground location rather thanbeing physically attached to the front or rear of a house or otherstructure. The outlet enclosure has an architecturally pleasingappearance but remains compliant with applicable standards such asUL-231 UL 514 A&D and NEC code 406.9B and NEMA enclosure standard 4X. Inthis manner, an installer is able to comply with all applicablestandards without having to install the outlet on the exterior of thebuilding or in an exterior waterproof electrical box mounted on conduit,with the installed outlet having an aesthetically pleasing appearance.

This invention is designed to be installed in exterior locations thatmay receive excessive moisture in the summer from irrigation systems andin the winter from normal weather. The invention is also designed to beinstalled in a garden location which can be discreetly hidden butreadily accessible.

The invention is also designed to be installed away from an existingstructure in high traffic areas either from foot traffic or equipment.In one embodiment, it is cast in high quality aluminum so that it canwithstand a major impact without being dislodged, disconnected ordamaged, and, unlike the prior art, it can withstand harsh weatherconditions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top, side perspective view of the exterior of the inventedoutdoor electrical outlet enclosure.

FIG. 2 is a top, side perspective view showing the invented outdoorelectrical outlet enclosure with its outer cylindrical cover in a raisedposition exposing a portion of the outlet cover, a base plate, a portionof the outlet and a door for the outlet in an open position.

FIG. 3 is a top, side perspective exploded view showing the outercylindrical cover, the outlet cover, the base plate, a GFCI outletscrewed to the door in a closed position and a threaded post forconnecting to the base plate from which the power supply enters.

FIG. 4 is a side elevation view of the enclosure taken along line 4-4 ofFIG. 1 , showing the outer cylindrical cover, the outlet cover, the baseplate and post and the outlet with two sockets.

FIG. 5 is a side elevation view taken along line 5-5 of FIG. 2 showingthe outer cylindrical cover in its raised position.

FIG. 6 is a is a side elevation view taken along line 6-6 of FIG. 2 .

FIG. 7 is a top, plan view of the outer cylindrical cover, outlet coverdoor, base plate and support post taken along line 7-7 of FIG. 4 .

FIG. 8 is a top, side perspective view of the exterior of an alternateembodiment of the invented outdoor electrical outlet enclosure.

FIG. 9 is a top, side perspective view showing the alternate embodimentof the invented outdoor electrical outlet enclosure with its outercylindrical cover in a raised position exposing a portion of the outletcover, a base plate, a post connector and a portion of the outlet.

FIG. 10 is a top, side perspective exploded view of the alternateembodiment showing the outer cylindrical cover, the outlet cover, thebase plate, the post connector a GFCI outlet and a threaded post forconnecting to the post connector from which the power supply enters.

FIG. 11 is a side elevation view of the enclosure taken along line 11-11of FIG. 7 , showing the outer cylindrical cover, the outlet cover, thebase plate, the post connector, threaded post and the outlet with twosockets.

FIG. 12 is a side elevation view taken along line 12-12 of FIG. 8showing the outer cylindrical cover in its lowered position.

FIG. 13 is a side elevation view taken along line 13-13 of FIG. 9showing the outer cylindrical cover in its raised position.

FIG. 14 is a top, plan view of the outer cylindrical cover, and baseplate taken along line 14-14 of FIG. 12 .

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIGS. 1, 2 and 3 an electrical outlet enclosure 9 includesan outlet cylindrical cover 11, a baseplate 13 on which is mounted a¾-cylinder outlet cover (in FIG. 3 ) which wraps partially around a WRGFCI electrical outlet 17 designed to meet UL and NEMA standards for awet location which may include a self-closing UL approved door cover 19to protect the socket or sockets 21 of the electrical outlet 17. The ¾cylinder outlet cover 15 leaves the outlet cover door, if present, andthe outlet socket or sockets accessible since it only surrounds ¾ of theelectrical outlet 17. The base plate is connected to a post 25 throughwhich electrical wires 45 (see FIG. 6 ) extend to connect to the GFCIelectrical outlet.

Such outlet door 19 can be a waterproof vertical cover made by HubbellIndustries which is spring loaded to close over the socket or sockets ofthe outlet. In an embodiment, the base plate 13 and ¾ cylinder outletcover 15 are formed by a casting technique to form an integrated part,though the two pieces can be formed separately and then connected viawelding or other connection mechanism. The outer cylindrical cover, baseplate and outlet cover are typically made of the same material which canbe any material suitable for an outdoor location that will not rust orcorrode such as brass with a minimum thickness of 24 mm ( 3/32″). In anembodiment, some parts, such as the outer cylindrical cover can beplastic.

As shown in FIG. 2 , the outer cylindrical cover 11 slides up and downon one or more vertical tracks 27, that are cut into or otherwise formedon the outer surface of the outlet cover 15, from a raised position to alowered position. In the raised position, the outlet cover door 19, ifincluded, is exposed so that it can be raised to expose the one or moresockets 21. In the lowered position, the outer cylindrical cover 11rests on the surface of the base plate 13. In an embodiment, there aretwo vertical tracks 27 formed on the outer surface of the outlet coveroffset by 180 degrees from each other. The two tracks ensure smoothoperation of the outer cylindrical cover as it is raised and lowered.

With reference to FIG. 3 , one or more set screws 31 or the like extendfrom a side of the outer cylindrical cover into the one or more verticaltracks. At the top of the track or tracks, in an embodiment, a reverse Lchannel 35 is used to hold the outer cylindrical cover in place when itis in its raised position by a slight rotation when the topmost positionis reached.

As best seen in FIG. 4 , inside the outer cylindrical cover 11 on itsbottom surface, in one embodiment, a rubber gasket 37 may be secured onthe base plate to prevent any moisture from entering the unit when theouter cylindrical cover is lowered over the outlet cover.

Additionally, a second rubber gasket 39 may be placed between outercylindrical cover 11 and outlet cover 15. The second rubber gasket alsomake the raising and lowering of the cover a smooth transition byprovided a buffer between the top of the outer cylindrical cover and thetop of the outlet cover 15. This second rubber gasket also providesfriction between the outer cylindrical cover and the outlet cover which,in an embodiment, holds in the outer cylindrical cover in place whenraised to its upper position without rotating the outlet cover asexplained below. Of course, gaskets 37 and 39 need not be made ofrubber, but can be any suitable somewhat resilient material with sealingand friction properties similar to rubber.

To operate the unit, the outer cylindrical cover is manually raised.When completely extended in the raised position, although gasket 39 willhold the outer cylindrical cover in place, in an embodiment, the outercylindrical cover may be turned to the left or right and held it inplace since the L channel 35 is perpendicular to a correspondingvertical track 27 and engage set screws 31. Once outer cylindrical cover11 is in the raised position, the outlet cover door 19, if present, canbe opened and a plug (not shown) inserted into a socket 21 of theelectrical outlet 17.

If used, the outlet cover door 19 is spring loaded to stay open whilethe plug is in the outlet, thereby protecting the plug and the outletfrom moisture. When the outer cylinder cover is raised. Thespring-loaded door, if used, will close over the plug to providingfurther protection from the weather. To disengage the plug, the outletcover door, if present, is raised slightly and the plug removed from thesocket, to let the outlet cover door, close over the socket or sockets.Then the outer cylindrical cover 11, if previously rotated, is rotatedto the right or left, as needed, and the outer cylindrical cover islowered so that it comes to rest on the base plate, either directly orvia contact with gasket 39. In the lowered position, the outercylindrical cover will protect the outlet from any irrigation system orother excessive weather conditions. In this manner, by locking theraised outer cylindrical cover, it is possible to operate the outletenclosure using only one hand so that the plug can be easily insertedinto socket 21 and subsequently removed.

To install the exterior ground outlet enclosure, the post 25 istypically a 1½″×18″ pipe inserted into the ground per code requirementsfor the electrical wires 45 (see FIG. 6 ). The wires pass up through thepipe that is screwed via threads 41 on post 25 into matching threads 43of base plate 13 as shown in FIGS. 3 and 4 and up through the outletcover 15, to be connected to the GFCI outlet 17. The GFCI outlet may beconnected with the Hubbell outlet door as is well known in the art.

To install the outer cylindrical cover 11 onto the installed baseplate/outlet cover combination, in an embodiment, set screws 31 areloosened so they do not extend past the interior wall of the outercylindrical cover. The outer cylindrical cover is lowered over the ¾outlet cover 15 so that the set screws align with vertical tracks 27.The outer cylindrical cover is lowered until it rests on base plate 13or its rubber gasket 37. Once the set screws are properly aligned withtracks 27, the set screws are tightened to extend into tracks 27. Thelength of the set screws may be set so that when the set screws arecompletely tightened, the set screws are effectively locked into placewith outer cylindrical cover 11, and extend into the vertical tracks 27without causing the outer cylindrical cover to be locked in place orotherwise difficult to be raised and lowered due to pressure from theset screws on outlet cover 15.

Alternatively, instead of set screws 31, outer cylindrical cover 11could be manufactured with pins or the like which extend from its innerwalls to engage with vertical tracks 27 in a similar manner as setscrews 31. The only requirement is a mechanism which enables outercylindrical cover 11 to be raised from and lowered onto base plate 13 sothat electrical outlet 17 and its sockets 21 can be accessed when outercylindrical cover 11 is raised.

FIGS. 8-14 show an alternate embodiment of the outlet cover where theelectrical outlet does not have a door to cover the outlet, but instead,the outer cylindrical cover extends over the base so as to completelyenclose the outlet. Two slots are added to the base when wires withplugs are inserted into each of the two sockets of the outlet.

As shown in FIG. 8 , outer cylindrical cover 51 is in a lowered positionon top of pipe 25. Outer cover 51 is shown in a raised position in FIG.9 exposing outlet holder 53, base 57 with slots 61 a and 61 b for wires63 a and 63 b which are not part of the invention, but are shown toillustrate their relationship with slots 61 a and 61 b. Also shown isdome shaped post connector 55 attached to base 57 for example by athreaded connection. Outlet holder 53 in the alternate embodiment is nota partial cylinder like ¾ cylinder 15 shown in FIGS. 3-7 , but is formedto receive an outlet without a door covering its sockets as explainedbelow.

FIG. 10 is an exploded view similar to FIG. 3 , except outlet 65 doesnot have a door to cover its sockets. Instead, outer cover 51 extendsover base 57 when it is lowered. Outer cylindrical cover 51 slides downtracks 71 which extend into base 57 instead of ending at base 57 as isthe case with tracks 27 shown in FIG. 3 . Set screws 69 extend throughcover 51 and engage with tracks 71 as cover 51 is raised and lowered.The set screws cooperate with outer cylindrical cover 51 in the samemanner as set screws 31 and outer cylindrical cover 11 of the FIGS. 1-7embodiment. Also shown in FIG. 10 are GFCI outlet 65, faceplate 65 a andoutlet box 65 b which exist in the prior art and do not form part of theinvention.

As best seen in FIG. 11 , outer cylindrical cover 51 in the closedposition completely covers base 57. Unlike the FIGS. 1-7 embodiment,there is no need for gaskets 31 and 39 between cover 51 and outletholder 53 or base 57. FIG. 11 also shows base 57 with an opening 67.Opening 67 is used to feed a cable with wires to connect to terminals onoutlet 65 in a manner similar cable 45 shown in FIG. 6 . In anembodiment, a separate ridged metal conduit is used to feed the cablethrough opening 67 to connect to the terminals as an added safetyprecaution. In this embodiment, outlet box 65 b can include a threadedopening at its bottom to receive the ridged metal conduit withcorresponding threads on one end so that the outlet box and ridged metalconduit can be threadedly connected, with the ridged metal conduitpassing through post 25.

FIG. 12 shows outer cylindrical cover 51 in its lowered position. Thatis, once the plugs are fully inserted, cover 51 is lowered to extendover base 57 with set screws 69 extending into tracks 71 guiding theouter cylindrical cover down. Of course, outer cylindrical cover 51 canbe lowered independent of the presence or absence of plugs inserted intothe sockets of outlet 65. Unlike the FIGS. 1-7 embodiment, outercylindrical cover 51 is lowered as soon as it is released to ensure thatit is not inadvertently left in its raised position. Also shown in FIG.12 is a lower portion 57 a of base 57 which in an embodiment isthreadedly connected to post connector 55.

FIG. 13 shows outer cover 51 in its fully raised position used to enableplugs with wires 63 a and 63 b (not shown in FIG. 13 ) to be pluggedinto the sockets of outlet 65. Once the plugs are fully inserted asshown in FIG. 12 , cover 51 is lowered to extend over base 57 with thewires attached to the plugs passing through slots 61 a and 61 b so thatoutlet 35 is completely covered by cover 51.

FIG. 14 is a top plan view which shows the arrangement of the elementsof the alternate embodiment with outer cylindrical cover 51 completelyenclosing outlet holder 53, outlet 65 and base 57 with openings 61 a and61 b for wires with plugs to be connected to sockets in outlet 65.

In an embodiment, the outlet enclosure is cast rather than cut out ofbrass or other suitable material bar stock, to reduce the waste andreduce the number of parts needed for the outlet enclosure. As in theFIG. 1-7 embodiment, some of the parts such as the outer cylindricalcover 51 may be made of plastic.

Accordingly, an outlet enclosure has been shown and described. Althoughvarious details and embodiments have been disclosed, the invention isdefined with reference to the following claims.

I claim:
 1. An outlet enclosure comprising: a base plate including atleast one slot for receiving a wire with a plug insertable into saidelectrical outlet and an opening for receiving a second wire; an outletholder for coupling to electrical outlet, said outlet holder includingat least one track extending in a vertical direction along an outersurface of said outlet holder; an outer cylindrical cover configured towrap completely around said outlet holder, said outer cylindrical coverslideable via said at least one track from a lowered position fullyenclosing said outlet holder to a raised position exposing said outletholder; and a post connector coupled to said base plate.
 2. The outletenclosure defined by claim 1 further comprising at least one set screwengagable with said at least one track to prevent a rotation of outercylindrical cover when said at least one set screw is engaged with saidat least one track.
 3. The outlet enclosure defined by claim 1 whereinsaid post connector includes threads to threadedly connect to a post. 4.The outlet enclosure defined by claim 1 wherein said outlet holderincludes a second track extending in a vertical direction along theouter surface of said outlet holder offset by 180 degrees from said atleast one track.
 5. The outlet enclosure defined by claim 1 wherein saidouter cylindrical cover extends over said base plate in said loweredposition.
 6. The outlet enclosure defined by claim 1 wherein said postconnector includes threads to threadedly connect to said base plate. 7.The outlet enclosure defined by claim 1 wherein said post connector isgenerally dome shaped and includes threads to threadedly connect to apost.
 8. The outlet enclosure defined by claim 1 wherein said outercylindrical cover includes on its inner side surface at least one pin orscrew configured to engage a corresponding one of said at least onetrack.
 9. The outlet enclosure defined by claim 8 wherein said at leastone pin or screw is removably connected to said outer cylindrical cover.10. The outlet enclosure defined by claim 1 wherein said post connector,said base plate and said outlet holder form an integrated unit.
 11. Theoutlet enclosure defined by claim 10 wherein said post connectorincludes threads to threadedly connect to a post.